Workpiece Diameter Research Articles

Influence of Tool Wear and Workpiece Diameter on Surface Quality and Prediction of Surface Roughness in Turning

In turning, tool wear and cutting vibration are inevitable, which have great influence on surface quality. Analyzing the influence mechanism of tool wear and cutting vibration on surface quality is important to achieve the accurate prediction of surface roughness before machining and improve machining quality. In this paper, a turning vibration experiment is conducted to reveal that the diameter of shafts is an important factor affecting the vibration amplitude and frequency. In addition, based on machining parameters, tool wear and workpiece diameter, this empirical model, the response surface method and a support vector machine are used to model and predict surface roughness. The fitting accuracy, prediction accuracy and generalization performance of the proposed methods are compared in detail. The results show that the response surface modeling method has the highest fitting accuracy, but the exponential empirical modeling method has the highest prediction accuracy and best generalization performance. Additionally, the prediction results indicate that the surface roughness increases with the increase in tool wear and decreases with the increase in workpiece diameter.

Investigation of the Role of the Initial Workpiece Diameter in Deformation Control in Electromagnetic Sheet Forming

Investigation of the Role of the Initial Workpiece Diameter in Deformation Control in Electromagnetic Sheet Forming

Determination of Optimal Machining Parameters Based on Roughness and Vibration Measurements of Pieces Produced by Whirling on a Lathe Machine

Worms can be produced using special machines or standard lathes equipped with a whirling thread-cutting device. A blank is placed on the mandrel and tightened using the three-jawed chuck of the standard lathe. If the workpiece diameter is excessively large, passage through the driven pulley is not possible, and the workpiece cannot be supported. Therefore, a new tool holder for whirling devices is needed. During the whirling process, vibrations in the form of machine velocity amplitudes were measured. After whirling was complete, roughness values were calculated. Using numerical procedures of Wolfram Mathematica 10, vibration peaks were extracted, from which frequencies and maximum amplitudes were determined. The data were then inputted into Design Expert, and the rotational speed and amount of separated material were optimized. The results of the study showed that the quality of the processed surface did not improve with processing in two passes of the tool. The measured vibration amplitudes on the lathe carrier and thread whirling attachment increased with cutting speed at the same cutting depth, whereas the quality of the machined surface was best at the smallest and largest cutting depths.

Modeling the Evolution of Casting Defect Closure in Ingots through Radial Shear Rolling Processing

This paper investigates the behavior of transverse defects under significant total strain in conditions of complex vortex metal flow implemented through the radial shear rolling (RSR) method. The aim of this study is to assess the applicability of RSR processing for the in-depth transformation of small ingots of special steel into bars, particularly for the manufacturing of structural elements in specialized construction projects such as nuclear power plants. Although a substantial total strain is anticipated to enhance the steel structure and contribute to defect closure, the question of the development or closure of potential casting defects remains unclear. To address this issue, model tests were conducted to simulate the implementation of RSR processing. Defect behavior data under very complex vortex metal flow and high strain conditions were obtained for the first time and have scientific merit. A small steel ingot with a 32 mm diameter, containing a simulated artificial defect in the form of a transverse through-hole with a 5 mm diameter, was employed. During rolling, the workpiece diameter was progressively reduced by 2 mm with each subsequent pass, reaching a final diameter of 20 mm. Additionally, to provide a more detailed visualization of the defect evolution process, the same defect was modeled in an aluminum bar over six passes, and changes in defect volume and shape were analyzed after each pass. A highly detailed 3D visualization of the actual defect evolution was achieved based on cross-sections from experimental workpieces. These data corresponded to the total strain levels obtained by finite element method (FEM) simulation. Notably, a consistent similarity was observed between the test results for both metals, revealing a reduction in defect volume of up to 67.7%. The deformational welding of defects in the outer sections, encompassing one-third of the rod’s radius, occurred in the initial passes. However, defects in the axial zone of the rods remained unclosed, lengthening and gradually decreasing proportionally to the elongation of the rod, akin to conventional rolling. Consequently, the radial shear rolling (RSR) method is unsuitable for ingots with substantial discontinuities in the axial zone post-casting. Nevertheless, the method ensures the total welding of defects located in the outer zones of the ingots, even with minor applied deformations and a slight decrease in the diameter of the deformed ingot. Such data were obtained for the first time and should contribute to future investigations in this field.

ANALISIS LAJU DEFORMASI PAHAT HSS PADA SIMULASI PEMBUBUTAN MESIN CNC DENGAN APLIKASI ANSYS

The demand to improve quality and productivity in the manufacturing industry underlies the analysis of tool deformation rates in the turning process. The methods used previously are considered inaccurate, and the provided information is incomplete. Therefore, detailed and accurate simulations are needed to determine deformation and strain values in HSS chisels. This study aims to obtain deformation and strain values on high speed steel (HSS) chisels in the process of turning ST42 steel workpieces using the finite element methods (FEM) method. The analysis was carried out using the ANSYS explicit dynamics application. This application aims to simulate complex physical phenomena by entering predetermined parameters, including diameter, spindle rotation, and workpiece and tool properties. HSS chisels are used in this simulation with ST42 steel workpieces. The variables in this study were the workpiece diameters of 30 mm, 40 mm, and 50 mm, with the same length of 200 mm. From the simulation results, it is evident that the maximum deformation value of the HSS tool on a diameter of 30 mm workpiece is 205.04 µm at a time step of 1.0 x 10-4 seconds. On a diameter of 40 mm workpiece, it is 205.19 µm at the same time step, and for a workpiece with a diameter of 50 mm, the tool deformation is 205.23 µm at the same time step. Additionally, the strain value on the HSS chisel with a workpiece diameter of 30 mm is 0.689 µm at a time step of 1.0 x 10-4 seconds. For a workpiece with a diameter of 40 mm, the strain is 0.783 µm at a time step of 1.0011 x 10-4 seconds, and on a workpiece with a diameter of 50 mm, the final strain on the tool is 0.866 µm at a time step of 1.0 x10-4 seconds.

Non-contact ultra-precision metrology of superfine cylinders with a developed two-dimensional coordinate measuring device

To address the issue of measuring force of a stylus that can move and/or hook up the measured workpiece with a small dimension in the contact measurement, a spectral confocal displacement sensor and an ultra-precision linear stage are employed to develop a two-dimensional coordinate measuring machine instead of the conventional stylus contact measurement to avoid the measuring force problem, by which the non-contact ultra-precision metrology can be achieved. A coordinate modeling-dividing method is proposed for the diameter and roundness measurement of the small cylindrical workpieces with a diameter of 0.5 mm and length of 50 mm, whose cross-sectional circle is divided into several equal arcs to be scanned by the developed two-dimensional coordinate measuring machine. Thus, a set of arcs, each of which consists of large numbers of coordinate points, can be obtained. The radius of each arc can be fitted by the least square method, and the arc profile can be characterized by a series of data processing. The diameter and roundness of the measured workpiece can be obtained by averaging these fitted arcs’ radii and stitching these arc profiles together, respectively. A preliminary measurement uncertainty analysis is carried out to verify the developed device and proposed method.

Numerical simulation of workpiece temperature field during radial shear rolling of biomedical Co-Cr-Mo alloy

This paper describes the analysis of temperature field of workpiece during radial shear rolling (RSR) of biomedical Co-28Cr-6Mo alloy. In the process of hot metal forming, the temperature distribution in the deformation zone has a significant influence on the quality and properties of the final product. In some cases, the deformation within a narrow temperature range is required to provide the desired properties. To obtain data on change in temperature, the computer simulation of RSR was carried out using finite element method. According to simulation results, the temperature distribution of bar depending on the variable process parameters such as temperature of workpiece, rotary velocity of rolls, elongation ratio, diameter of workpiece, and temperature of tool was evaluated. It was determined that the most significant parameters influencing on the distribution of the temperature field are the workpiece heating temperature and the rolling speed. The RSR process makes it possible to effectively manage the distribution of temperature field due to selecting technological parameters and, thereby, control the formation of the alloy structure. The data obtained can be useful for developing the modes of RSR of Co–Cr–Mo alloy.

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes.

Any industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600 alloy with untreated zinc and cryogenically treated zinc electrodes was investigated. The controllable parameters included the current (IP), pulse-on time (Ton), and pulse-off time (Toff), whereas the wire diameter, workpiece diameter, dielectric fluid flow rate, wire feed rate, and cable tension were held constant throughout the experiments. The significance of these parameters on the material removal rate (MRR) and surface roughness (Ra) was established using the analysis of the variance. The experimental data acquired using the Taguchi analysis were used to analyze the level of influence of each process parameter on a particular performance characteristic. Their interactions with the pulse-off time were identified as the most influential process parameter on the MRR and Ra in both cases. Furthermore, a microstructural analysis was also performed via scanning electron microscopy (SEM) to examine the recast layer thickness, micropores, cracks, depth of metal, pitching of metal, and electrode droplets over the workpiece surface. In addition, energy-dispersive X-ray spectroscopy (EDS) was also carried out for the quantitative and semi-quantitative analyses of the work surface and electrodes after machining.

Identification of a Workpiece Temperature Compensation Model for Automatic Correction of the Cutting Process

This article describes a system for measuring and compensating for errors resulting from the cutting process in order to improve the accuracy of the workpiece. Measurements were performed by means of an automatic measurement unit. The diameter of the workpiece was measured at two points, and at the same time, the temperature at the end face of the workpiece was measured. These measurements were used in Statistical Process Control (SPC). Based on the measured values, the process stability was checked and an error correction value was determined for the next item. Moreover, the value of the correction was influenced by the assumed value of tool wear, in accordance with the adopted model, and the possibility of achieving the assumed surface quality. The diameter of the workpiece for SPC purposes was measured under industrial conditions using an automatic measurement unit, which indicates that the temperature of the workpiece during the measurement was significantly higher than the reference temperature. The study focuses on the possibility of identifying a workpiece temperature compensation model in measurements of the workpiece diameter for the purpose of introducing an additional change in the correction value. It was found that a model with a constant correction value and a linear model poorly reflect the nature of the changes. On the other hand, the Autoregressive with Extra Input (ARX) model and the Nonlinear Autoregressive with Extra Input (NLARX) model, with a neural network, are able to map the inertia of the system and map the process with greater accuracy. In this way, measurements performed in industrial conditions can more accurately determine the possibility of achieving the assumed tolerance of the finished product. At the same time, the research shows that the temperature compensation model is nonlinear, and that the maximum possible machining accuracy of the workpiece can be achieved thanks to the repeatable measurement and compensation technique.

Effect of tool posture on chatter vibration in turn-milling

Turn-milling is a machining method for milling a rotating work material. It has attracted attention as a method for milling difficult-to-cut materials with high efficiency. The milling process enables lower cutting temperature and high chip disposability compared to conventional turning resulting from the interrupted cutting. In addition, turn-milling allows for a larger reduction of workpiece diameter in one tool path due to the higher degree of freedom in the cutting tool posture motion. In order to achieve high-efficiency cutting, it is important to avoid chatter vibration, which has several negative effects, including poor surface quality, machine tool damage, etc. However, few studies have focused on the chatter vibration of turn-milling, and most of those have focused on orthogonal turn-milling. The object of this study is to investigate the effect of tool posture on chatter vibration in 5-axis turn-milling. Instantaneous cutting forces were obtained based on a point cloud simulation model, in which the tool and workpiece are expressed as points, and the chatter stability of turn-milling was predicted by time domain simulation. Cutting experiments were then performed under several conditions with different tool postures, and we confirmed that the predicted chatter stability limits agreed well with the experimental results. In addition, the simulations showed that tool posture has a significant effect on the change in the contact area between the tool and workpiece, which in turn affects the occurrence of chatter vibration.

MULTIPLE PROCESS PARAMETER OPTIMIZATION OF FORWARD EXTRUSION PROCESS ON AA 2024

Extrusion is a simple metal forming process in which a block of metal is forced through a die orifice with a certain shape under high pressure. This extrusion process is influenced by many process parameters such as die angle (DA), ram speed (RS), coefficient of friction (COF), Extrusion ratio, Die land height, work piece diameter and length, material properties etc. In extrusion process, extrusion force is crucial parameter, the flow of metal and hence the extrusion force is significantly influenced by the above parameters which results in quality of the product. The present study numerically investigates the influence of major process parameters such as die angle, ram speed, coefficient of friction on the extrusion process. The AA2024 material is chosen as work piece material and the extrusion force and damage is considered as the output responses. The input process parameters are varied in three levels (Level - 1: 10° DA, 1.6mm/min RS, 0.06 COF; Level - 2: 20° DA, 3.2mm/min RS, 0.08 COF; Level - 3: 30° DA, 4.8mm/min RS, 0.01 COF). Numerical simulations are performed by using DEFORM 3D software. The simulations are conducted as per L27 orthogonal array. From the results it is observed that Increase of die angle, ram speed and coefficient of friction increases the extrusion force. The die angle has highest (86.45%) influence on the extrusion force, then after ram speed (6.60%). The coefficient of friction has insignificant influence (0.55%). It is also noticed that the damage is considerable after the 20° die angle. A multi parameter optimization is also done by using the Grey relation analysis by considering the equal weightage of extrusion force and damage. The optimum levels of input process parameters for the minimum extrusion force and damage is DA level 1, RS level 1, and COF level 3.

Mechanistic modeling of cutting forces in high-speed microturning of titanium alloy with consideration of nose radius

Microturning is a micromechanical machining process used to produce microcylindrical or axially symmetrical parts. Microcylindrical parts are mainly used in microfluidic systems, intravenous micromotors, microsurgical applications, optical lens applications, and microinjection systems. The workpiece diameter is very small in microturning and therefore is greatly affected by the cutting forces. For this reason, it is important to predict the cutting forces when machining miniature parts. In this study, an analytical mechanistic model of microturning is used to predict the cutting forces considering the tool nose radius. In the semi-empirically developed mechanistic model, the tool radius was considered. A series of semi-orthogonal microturning cutting tests were carried out to determine the cutting and edge force coefficients. The mechanistic model was generalized depending on the cutting speed and depth of cut by performing multilinear regression analysis. In the study, the depth of cut (ap = 30–90 µm) and feed values (f = 0.5–20 µm/rev) were selected considering the nose radius and edge radius of the cutting tool. The experiments were carried out under high-cutting speeds (Vc = 150–500 m/min) and microcutting conditions. Ti6Al4V alloy was used as the workpiece material and the tests were carried out under dry cutting conditions. Validation tests for different cutting parameters were carried out to validate the accuracy of the developed mechanistic model. The results showed that the difference between the mechanistic model and the experimental data was a minimum of 3% and a maximum of 24%. The maximum difference between the experimental and the model usually occurs in forces in the tangential direction. It has been observed that the developed model gives accurate results even at a depth of cut smaller than the nose radius and at feed values smaller than the edge radius.

Accurate estimation of workpiece dimension in plunge grinding without sizing gauge

In the cylindrical grinding process, the residual grinding allowance is left owing to the rubbing of the abrasive grains and the elastic deformation of the grinding system caused by the large normal grinding force. Therefore, a sizing gauge is generally used to monitor the workpiece diameter during the process. However, the sizing gauge disturbs the grinding operations, such as loading and unloading the workpiece. In this study, a new method for estimating the grinding stock of a ground workpiece is proposed. In the proposed method, the grinding stock can be estimated without a sizing gauge. The removed volume of the workpiece can be calculated from the power consumption of the wheel motor, which is easily measured. Before the grinding experiments, the specific grinding energy is determined from several grinding results. During the grinding process, the grinding stock of the ground workpiece was estimated using the determined specific grinding energy. It was confirmed that the grinding stock could be accurately estimated under several grinding conditions.

Comparison on Milling Force Model Prediction of New Cold Saw Blade Milling Cutter Based on Deep Neural Network and Regression Analysis

A four factors and three levels orthogonal milling force (MF) test is designed, which qualitatively obtains the influence of four factors, namely workpiece material, workpiece diameter, milling speed and feed per tooth, on MF of the new cold saw blade milling cutter (NCSBMC), then further verifies the reliability of test data with simulation analysis of MF. The multiple linear regression analysis and deep neural network (DNN) are used to accurately fit and predict the magnitude of MF in three directions of NCSBMC, taking into account the influence of workpiece material factors on MF. Compared with the results of empirical formula, DNN has higher prediction accuracy. The research results provide theoretical guidance for the optimization of milling parameters in actual machining process.

On-machine diameter measurement of a cylindrical workpiece with a reference artefact

A system for on-machine diameter measurement of a ceramic cylindrical workpiece on a precision grinding machine is developed by employing a commercial optical micrometer, which can measure the diameter of a workpiece in various sizes. One of the drawbacks of the optical micrometer is its poor thermal stability, which could affect the on-machine diameter measurement in a machine shop where the room temperature is not controlled well. To address the issue, in this paper, a comparative measurement method with a calibrated reference artefact having identical material and nominal diameter with respect to a ceramic workpiece is newly proposed. In the proposed comparative method, the workpiece diameter is evaluated through detecting its deviation from that of the reference artefact calibrated by using a high-precision measuring instrument such as a coordinate measuring machine in advance of the on-machine measurement. Meanwhile, in the comparative measurement method, the uncertainty of the reference artefact should also be taken into consideration as a source of uncertainty. In this paper, measurement uncertainty analysis is carried out for the proposed comparative method based on GUM, while verifying the uncertainty of the reference artefact diameter through numerical calculations by a Monte Carlo method.

Numerical investigation of the radial cold rolling process of the grooves

The radial cold rolling process is widely used in industry due to the advantages of chip removing processing. In this study, circular complex profiles were formed by cold-rolling with radial feed, using a patented device with two roller-tools. By achieving several numerical simulations of the radial rolling process, the study aimed to establish the influence that the maximum set force and the diameter of the workpiece have on the productivity of the process and the quality of the formed trapezoidal and metric grooves. The numerical simulations were performed with ABAQUS/Explicit software and by using a previously validated finite element model. The penetration curve of the roller-tools in the material was introduced in the simulation as an analytical function and was determined based on experimental researches. To express the dependency of the penetration curve coefficients on other rolling conditions, a multivariable analysis using a design of experiments technique was performed. The parameters that result from numerical simulations and were analyzed in this study are the profile forming time, the maximum radial force, the distribution of the equivalent strains in the axial section of the profiles, and the profile dimensions. The conclusions that were drawn from the analysis of the results regarding the influence of the set maximum force and the workpiece diameter on the analyzed parameters of the numerical simulations, together with the definition of efficient process criteria, allowed also the identification of the optimal conditions of the rolling process.

Perubahan Sifat Mekanik Hasil Pengelasan Gesek Aluminium 6061 Akibat Perubahan Temperatur Lingkungan

<p class="Abstract"><span lang="EN-GB">Friction welding is a welding technique that utilizes heat due to surface friction between a rotating and pressing workpiece. This study aims to analyze the effect of environmental temperature variations on the mechanical properties of Al 6061 alloys, friction welding specimens with variations in room temperature (27ºC), 50 ºC, 75 ºC, 100 ºC, 125 ºC, and 150 ºC. Welding is carried out using a lathe with a rotation speed of 1600 rpm, a workpiece diameter of 15 mm, a champer angle of 15º, a friction force of 65 bar for 6 seconds, and a final compressive force of 325 bar for 60 seconds. Changes in mechanical properties in terms of tensile strength and hardness. The results showed that the higher working environment temperature produced greater tensile strength than Al 6061 friction weld joints. From macro-micro observations, it was found that specimens with large tensile strength (specimens welded at 100 ºC, 125 ºC, and 150 ºC) had a large area (Zpl) and finer granules when compared to specimens with small tensile strength (specimens welded at room temperature (27 ºC), 50 ºC and 75 ºC).</span></p>

Characteristic of friction welding weld joint of AA6061 on elevated environmental temperature

Rotary Friction Welding is a solution in addressing the poblems in welding of material difficult to weld by fusion welding, such as AA6061 aluminium alloy. Fusion welding is difficult to apply to aluminium alloy because of porosity and crack which often occur during solidification. From the research on friction welding of AA6061, it can be conclude that excessive welding temperature of friction welding may result in thermal softening in weld zone and HAZ. The excessive cooling rate after friction welding run will affect to formation of hard and brittle of weld zone. Increase of environmental temperature above room temperature will accelerate workpiece to achieve solid state condition and lowering difference between weld peak temperature and inital weld temperature (ΔT) which mean decreasing of coooling rate. In this research, environmental temperature were varied of 27 °C (room temperature), 50 °C, 75 °C, 100 °C, 125 °C dan 150 °C. Some parameters are set constant such as rotation speed of 1600 rpm, friction pressure of 65 bar or 65 kg.cm−2, friction time (tf) of 6 seconds, forging pressure of 325 bar or 325 kg.cm−2, forging time of 60 seconds, contact diameter of workpiece of 15 mm and the workpiece chamfer angle of 15°. The contact area is divided into three zones, which are the plastic deformation zone (Zpl), the partial deformation zone (Zpd) and the non-deformed zone (Zud). The higher the environmental temperature will produces the wider plastic zone and plastic deformation zone (Zpl + Zpd). The higher the environmental temperature will causes the yield strength of the AA 6061 friction weld joint to increase which modelled as y = 3E-05x2 + 0.0033x + 16.582. Likewise, the tensile strength of the AA 6061 friction weld joint also increases which modelled as y = 3E-05x2 + 0.0026x + 18.119. When comparing the hardness of rotating workpiece side (spin) with workpiece side pressing (press), the previous one is higher at all variations of the temperature. From the photograph of the microstructure of base metal of Al 6061, dark particles (Mg2Si) and gray particles (Fe3SiAl12) are present in the Al matrix. The grain structure of Zud is bigger than Zpd and Zpl. Zpd microstructures at all environmental temperatures form smaller granular structures than base metal grains. Zpl microstructure in workpieces with environmental temperature of 27 °C, 50 °C, 75 °C and 100 °C were formed in small granular structure with Mg2Si (black) and Fe3SiAl12 (gray) structure which spread evenly. However Zpl microstructure with environmental temperature of 125 °C and 150 °C seems to enlarge, especially the structure of Fe3SiAl12 (gray), due to overheat and excessive softening.

Temperature Increase during Isothermal Forging of Ti-5Al-2Sn-2Zr-4Cr-4Mo Alloy Using a 1500-Ton Forging Press

In this study, the temperature increase of the Ti-17 alloy (Ti–5Al–2Sn–2Zr–4Cr–4Mo, wt.%) during isothermal forging in the (α + β) dual-phase region was investigated using large-size workpieces forged between hot dies in a 1500-ton forging press. The temperature increase was predicted using finite element analysis (FEA). The tip of a thermocouple was inserted into the center of the workpiece (diameter: 100 mm; height: 50 mm). The forging temperatures were 1023 K (750 °C) and 1073 K (800 °C) in the (α + β) dual-phase region. The strain rate was 0.05 s−1 and 0.5 s−1 at each temperature. Meanwhile, the compression percentage was 75%. The true stress–true strain curves were inversely obtained by fitting the load–stroke curves using the FEA. The predicted temperature was in a good agreement with that in the experimental results when the value of 1.0 was used as the conversion factor for plastic deformation energy to heat energy in the FEA under the current forging conditions. At the strain rate of 0.5 s−1, the temperature instantly increased to a β-transus temperature in 3 s at 1073 K (800 °C). In contrast, the temperature logarithmically increased at both 1023 K (750 °C) and 1073 K (800 °C) at 0.05 s−1 in 28 s (e.g., 42 K at 1023 K (750 °C)). The obtained true stress–true strain curves indicate that flow softening occurred during the forgings, which is attributed to dynamic recrystallization and/or dynamic recovery. The temperature increase in the Ti-17 alloy was smaller than that in the Ti–6Al–4V alloy under the same forging condition.

Influence of Process Parameters on Material Removal Rate in Electrical Discharge Machining Cylindrical Shaped Parts

This paper aims to find the impact of Electric Discharge Machining (EDM) factors on material removal rate (MRR) for 90CrSi alloy steel. Five three-level factors including pulse on time (Ton), pulse off time (Toff), pulse current (IP), server voltage (SV), and diameter of work-piece (dw) are investigated to explore their contribution on MRR by using Taguchi method in twenty-seven experiments based on an orthogonal array L27 (35). The findings realize that MRR is the most affected by the pulse current while the effect of the dw is the smallest. Based on ANOVA analysis, an optimal model of MRR has been developed and verified by comparing with the experiment result. The applicability of this proposed method can be used for further studies in EDM process.